Flexible postal mailer and blank therefor

ABSTRACT

A postal mailer includes a first main panel and a second main panel opposite the first main panel and opposed first and second peripheral side panels extending between the first main panel and the second main panel. One or more score lines extend across each of the first and second main panels and an opening is formed in each of the first and second peripheral side panels and extends between the first and second main panels.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present application claims priority, as a continuation-in-part type application, under 35 U.S.C. § 120 to U.S. patent application Ser. No. 11/807,038, filed May 25, 2007, currently pending, which, in turn, claims the benefit of priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 11/705,321, filed Feb. 12, 2007, currently pending. Each of the aforementioned applications is incorporated herein by reference in its entirety.

BACKGROUND

The present disclosure relates to mailing boxes and, more particularly, to flexible postal mailers or shipping cartons and blanks therefor. The embodiments described herein are particularly well suited for flat-size mail pieces for processing by automated processing equipment commonly employed by postal services such as the United States Postal Service and others.

Commonly, automated mail processing equipment requires that flat-size mail pieces meet certain automation standards, including turning ability and deflection requirements. However, a flexible mail piece must be sufficiently rigid to meet certain deflection requirements, that is, one end must be able to extend from a surface, unsupported without deflecting by more than a prespecified amount.

Flat-size mail pieces meeting applicable standards are entitled to reduced, automation postage rates. Flat-size mail that does not meet the turning ability and deflection requirements cannot be processed by automated equipment and, thus, is more expensive to mail since it does not qualify for automation postal rates.

There are certain instances wherein a rigid box is preferred over a flexible envelope for mailing packages. For example, response rates to direct mail marketing programs are generally higher for rigid boxes than for envelopes. Also, rigid boxes generally provide better protection of the contents against damage than envelopes. However, such rigid boxes have minimal, if any flexibility. Additionally, some prior art flexible mail pieces may require that shrink wrap be used to ensure that the contents remain enclosed, with such additional packing materials being of both economic and environmental concern. Accordingly, the present disclosure contemplates a new and improved postal mailer and blank therefor which overcome the above-referenced problems and others.

SUMMARY

In one aspect, a postal mailer is provided which includes a first main panel and a second main panel opposite the first main panel, opposed first and second peripheral side panels extending between the first main panel and the second main panel, and opposed first and second end panels extending between the first main panel and the second main panel. One or more score lines extend across each of the first and second main panels and one or more openings formed in each of the first and second peripheral side panels and extending between the first and second main panels.

In another aspect, an improved postal mailer of generally box-like construction is provided having opposing first main and second main panels and opposing peripheral side walls and opposing end walls extending therebetween, wherein the improvement comprises one or more of score lines extending across the first main panel of the postal mailer, one or more of score lines extending across the second main panel of the postal mailer, and one or more openings formed in each of said peripheral side walls and extending between said one or more of score lines extending across the first main panel of the postal mailer and said one or more of score lines extending across the second main panel of the postal mailer.

In another aspect, a postal mailer blank is provided, comprising a plurality of wall panels hingedly connected together for forming a first main panel, a second main panel opposing said first main panel, opposing side walls, and opposing end walls. One or more score lines extend across said first main panel and one or more score lines extend across said second main panel. One or more openings are provided in said panels for forming one or more openings in said opposing side walls and extending between said first and second main panels.

In another aspect, an improved postal mailer of generally box-like construction is provided having opposing first main and second main panels and opposing peripheral side walls and opposing end walls extending therebetween, one or more of score lines extending across the first main panel of the postal mailer, one or more of score lines extending across the second main panel of the postal mailer, and wherein the improvement comprises one opening formed in each of said peripheral side walls and extending between said one or more score lines extending across the first main panel of the postal mailer and said one or more score lines extending across the second main panel of the postal mailer.

In another aspect, a postal mailer blank is provided, comprising a plurality of wall panels hingedly connected together for forming a first main panel, a second main panel opposing said first main panel, opposing side walls, and opposing end walls. One or more score lines extend across said first main panel and one or more score lines extend across said second main panel. One opening is provided in said panels for forming one opening in each of said opposing side walls and extending between said first and second main panels.

One advantage of the presently disclosed postal mailer is found in that it allows the mail piece to retain the advantages of a rigid box while complying with flexibility requirements for automated mail processing systems.

Another advantage of the present device is that the box can bend upwards and downwards without damaging the contents.

Still another advantage of the present development is found in that may allow reduced automation postal rates to be claimed.

Yet another advantage of the present invention is found in that the amount of packaging material may be reduced in that a desired degree of flexibility can be provided in a box of relatively rugged construction, thereby avoiding the need for additional packaging materials such as shrink wrap.

Other benefits and advantages of the present disclosure will become apparent to those skilled in the art upon a reading and understanding of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings, wherein like reference numerals are used for like or analogous components throughout the several views, are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention.

FIG. 1 is a top isometric view of a postal mailer in accordance with a first exemplary embodiment.

FIG. 2 is a bottom isometric view of the embodiment shown in FIG. 1.

FIG. 3 is a plan view of a mailer blank which may be used to construct the embodiment appearing in FIG. 1.

FIG. 4 illustrates the manner of bending of the postal mailer embodiment of FIG. 1.

FIG. 5 is a top isometric view of a second exemplary embodiment postal mailer.

FIG. 6 is a top isometric view of a third exemplary embodiment postal mailer.

FIG. 7 is an exploded isometric view of a fourth exemplary embodiment postal mailer.

FIG. 8 is an exploded isometric view of a fifth exemplary embodiment postal mailer.

FIG. 9 is a top isometric view of a postal mailer in accordance with a sixth exemplary embodiment.

FIG. 10 is an exploded isometric view of a postal mailer in accordance with a seventh exemplary embodiment.

FIG. 11 is a plan view of a mailer blank which may be used to construct the embodiments appearing in FIGS. 9 and 10.

FIG. 12 is a top isometric view of a postal mailer in accordance with an eighth exemplary embodiment.

FIG. 13 is an exploded isometric view of a postal mailer in accordance with a ninth exemplary embodiment.

FIG. 14 is an exploded isometric view of a postal mailer in accordance with a tenth exemplary embodiment.

FIG. 15 is a plan view of a mailer blank which may be used to construct the embodiments appearing in FIGS. 12, 13 and 14.

FIG. 16 is a top isometric view of a postal mailer in accordance with an eleventh exemplary embodiment.

FIG. 17 is a bottom isometric view of the embodiment shown in FIG. 16.

FIG. 18 is a plan view of a mailer blank which may be used to construct the embodiment appearing in FIG. 16.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIGS. 1 and 2, there is shown a first embodiment postal mailer 30 having an upper main panel 32 and an opposing lower main panel 34, the upper and lower panels 32 and 34 being generally planar and generally rectangular and of substantially the same dimension. As used herein, the terms “upper” and “lower” refer to the relative orientation as shown in FIG. 1. Opposing first and second upstanding side walls 36 and 38, respectively, extend between the upper panel 32 and the lower panel 34. An opening 42 is defined at a first end, shown generally as 40, of the mailer 30.

One or more closure flaps may be provided to close the opening 42. In the depicted embodiment, a pair of lateral closure flaps 46 and 48 is attached to the side walls 36 and 38, respectively. An end closure flap 50 is attached to the upper panel 32 and includes a distal portion 52 to be received through the opening 42. The end closure flap 50 also includes a proximal portion 54, which extends vertically between the upper and lower panels 32 and 34, the proximal portion 54 defining an end panel for covering the opening 42 when the end closure flap 50 is in the closed position.

In the depicted preferred embodiment, a tongue 56 extends from the lower panel 34 and may be received within an aligned slot 58 in the end closure flap 50 intermediate the proximal portion 54 and distal portion 52 for securing the end closure 50 in the closed position. A like end closure flap 50 may also be provided at a second end, shown generally as 60, opposite the first end 40. It will be recognized that the end closure means depicted herein are exemplary and illustrative only and any other known permanent or releasable end closures may also be employed, including closure flaps having an adhesive thereon, or the like.

A region 70 of increased flexibility extends transversely with respect to an axis of the mailer 30, preferably the long axis of the mailer 30, and includes a plurality of score lines 72 (shown in broken lines) extending transversely across the upper panel 32 and a corresponding plurality of score lines 74 extending transversely across the lower panel 34. A plurality of openings 76 and 78 are formed in each of the side walls 36 and 38, respectively, and are preferably slits or otherwise narrow elongate openings. Each of the openings 76 and 78 extends between one of the upper panel score lines 72 and an axially aligned one of the lower panel score lines 74, defining flexible panels or regions 77 between or adjacent the openings 76, 78.

Each of the openings 76 and 78 may include an enlarged opening 80 formed at each end thereof to prevent the openings 76, 78 from tearing or further propagating, e.g., during handling or flexing of the mail piece. The openings 80 may be further reinforced, e.g., via grommets or the like.

In the depicted preferred embodiment of FIGS. 1 and 2, there is one bending region 70 having three sets of score lines 72, 74 and three sets of corresponding aligned openings 76, 78. Preferably, the region 70 is generally centered between the ends of the mailer so that the mail piece will exhibit the same flex characteristics, regardless of the end-to-end orientation of the mail piece when it enters the mail handling equipment.

It will be recognized, however, that other numbers of flexible regions 70 and/or other numbers of sets of score lines 72, 74 and slits 76, 78 per flexible region 70 are contemplated. Preferably, the number of flex regions 70 is in the range of 1 to 4 (although other numbers are contemplated), which may be axially spaced between the ends 40 and 60 of the mail piece, and more preferably, generally equally or symmetrically spaced therebetween. Preferably, the number of pairs of score lines 72, 74 and corresponding pairs of sidewall openings 76, 78 per flex region 70 is in the range of 1-5, more preferably 2-5, and most preferably 3, although other numbers thereof contemplated.

Referring now to FIG. 5, there is illustrated an exemplary embodiment mailer 130 similar to the embodiment 30 as illustrated in FIGS. 1 and 2, but wherein the region 70 has only two score lines 72, two score lines 74 (not shown) and two corresponding pairs of openings 76, 78. Referring now to FIG. 6, there is illustrated an exemplary embodiment mailer 230 similar to the embodiment 30 illustrated in FIGS. 1 and 2, but wherein there are plural preferentially bendable regions 70.

Referring again to FIGS. 1 and 2, an exemplary region 82 for printing an address or affixing an address label is shown. The region 82 may be an opening, e.g., a die cut opening, or a transparent window and the address may appear on the contents to be mailed. Bar codes, labels, and other indicia may be applied to or printed on the mailer 30. Alternatively, an address label may be affixed over the region 82, e.g., held in place via an adhesive or a shrink wrap film provided about the mail piece. Where shrink wrap is applied, the address or other labels or indicia may be applied under the shrink wrap layer for transvisualization therethrough, or, on the shrink wrap layer itself. An optional opening 83, which may optionally have a transparent film window or the like, may also be provided, for example, to allow viewing of the mail piece contents or a sample of the mail piece contents.

Referring now to FIG. 3, and with continued reference to FIGS. 1 and 2, the mailer 30 may be formed from a flat blank 31 as seen in FIG. 3. The blank 31 may be formed of any suitable material for folding to form a generally rigid box, such as paperboard, cardboard, card stock, plastic, plastic-coated paper, or other foldable sheet material.

The blank 31 may be cut to the desired size and peripheral shape, and the slits, openings, score lines, etc., as described herein may be formed thereon via conventional methods, such as die cutting from one or more sheets of stock material. The blank 31 includes score lines 90 and 92 defining the opposite long edges of the upper panel 32. As used herein, the term “score line” or “fold line” includes any indentation, impression, or partial perforation formed in the stock sheet material forming the blank 31 along a predetermined line and which is adapted to allow a preferential folding of the stock material therealong.

The blank 31 further includes score lines 94 and 96 defining the opposite long edges of the lower panel 34. Score lines 98 define the opposite width edges of the upper panel 32 and provide a preferential fold line between the upper panel 32 and the closure end flaps 50. Score lines 98 also provide preferential fold lines for the lateral flaps 46. Score lines 108 provide preferential fold lines for the lateral flaps 48. Score lines 100 are provided on each of the flaps 50 to provide a preferential fold line on each flap 50 between the proximal and distal portions 54 and 52, respectively. Slits 102 in the lower panel 34 define the proximal portion of the tabs 56, each of which includes proximal and distal score lines 104 and 106, respectively, forming preferential fold lines therealong.

The score lines 72 transversely extend across the upper panel 32 between the fold lines 90 and 92. The score lines 74 transversely extend across the lower panel 34 between the score lines 94 and 96. The slits 76 in the assembled mailer 30 may be preformed in the blank 31 and extend transversely between the fold lines 92 and 94 to define panels 77 therebetween. The slits 78 a and 78 b in the sidewall panels 38 a and 38 b, respectively, overlap in the assembled mailer 30 to form the slits 78 in the assembled mailer. The enlarged openings 80 in the assembled mailer are formed by the openings 80 and the cutout regions 80 a and 80 b which may likewise be precut on the blank 31. If openings are to be provided in the regions 82 and/or 83, such openings may be die cut or otherwise preformed in the blank 31.

In constructing the mailer 30 from the blank 31, the blank is folded at right angles along the lines 90, 92, 94, and 96 and the flaps 38 a and 38 b are secured together in overlapping fashion to form the side wall 38. The flaps 38 a and 38 b may be secured together with an adhesive, mechanical fastener, or other fastening technique. For example, in the case of a plastic or plastic-coated stock material, the flaps 38 a and 38 b may be thermally fused to form the sidewall 38.

To close one or both of the ends 40 and 60 of the mailer 30, the end flaps 50 are each folded along the fold lines 98 and 100. The distal portions 52 are inserted within the respective openings 42 such that the proximal portions 54 each form a peripheral end wall extending between the upper panel 32 and the lower panel 34. The tabs 56 are each folded along the lines 104 and 106 and the distal end of each tab 56 is inserted into the corresponding slot 58 in the respective end flap 50.

In constructing the assembled mailer 30, the blank 31 is not folded along the fold lines 72 and 74. The fold lines 72 and 74 remain substantially unfolded in the assembled article 30 to allow the mail piece to remain substantially rigid. Instead, the score lines 72 and 74 are intended only to provide fold lines along which the mailer 30 will preferentially bend if a bending stress is applied to the mail piece, such as during automated processing or handling of the mail piece.

The slits 76 also assist in facilitating a flexing or bending along the bending region 70 defined by the score lines 72, 74 when a bending stress is applied to the mail piece. The flexible panels 77 can flex as necessary, thereby helping to confine any flexing or bending of the mail piece 30 to the bending region 70.

FIG. 4 shows a somewhat schematic illustration of the article 30, illustrating the manner in which the article 30 may bend or flex as it passes between concentric radii 12 and 14, which are representative of a drum or roller employed for changing the direction of travel of a mail piece in a postal handling or processing system. Since bending is substantially confined to the bending region 70, the mailer 30 may advantageously be used for shipping inflexible and/or fragile articles which are packaged at one end or the other of the mailer 30 and do not extend into the region 70. By providing score lines on both the upper and lower panels of the mailer 30, the mailer may bend in either direction, allowing the mail piece to be processed regardless of whether the mail piece enters the processing system in right-side up or upside-down orientation.

Referring now to FIG. 7, there appears a further embodiment mailer system including an outer box 30, which may be as described above by way of reference to FIGS. 1 and 2, and which further includes an inner sleeve 330. The inner sleeve 330, which is shown in fragmentary view in FIG. 7 for ease of exposition, has an outer dimension that is sized to be received within the interior of the box 30. The inner sleeve 330 includes an upper main panel 332 and an opposing lower main panel 334, the upper and lower panels 332 and 334 being aligned with the corresponding panels 32 and 34, respectively, of the outer box 30 when the inner sleeve member 330 is received within the outer box 30. Opposing first and second upstanding side walls 336 and 338, respectively, extend between the upper panel 332 and the lower panel 334.

A region 370 of increased flexibility extends transversely with respect to an axis of the mailer 330, and includes transversely extending score lines 372 on the upper panel 332 and corresponding score lines 374 on the lower panel 334. The flexible region 370 also includes openings 376 in the side wall 336 and corresponding openings 378 in the side wall 338. The openings 376 and 378 are preferably elongate slits having enlarged openings 380 at each end.

When the inner sleeve member 330 is received within the outer box 30, the flexible region 370 is in axial alignment with the flexible region 70 of the outer box member 30. The inner sleeve 370 and may optionally be fixed to the outer carton 30 via a pin, clip, or other fastener. The sleeve 370 may include an address region 382 aligned with the region 82. In the case of an outer box 30 having an opening or window 82, the region 382 may have an address or address label thereon to be viewed through the window 82. Alternatively, the region 382 may be an opening or window for viewing an address printed on the contents to be mailed.

Referring now to FIG. 8, there appears a further mailer 430 of a set up box type including an upper box member 530 and a lower box member 630. The upper box member 530 includes a main panel 532 bounded by a peripherally raised wall including a pair of opposed end panels 537 and a pair of opposed side panels 536.

A region 570 of increased flexibility extends transversely with respect to an axis of the upper box member 530, and includes transversely extending score lines 572 on the main panel 532. The flexible region 570 also includes openings 576 in the side walls 536, which are preferably elongate slits having enlarged openings 580 at each end.

The lower box member 630 includes a main panel 634 bounded by a peripherally raised wall including a pair of opposed end panels 637 and a pair of opposed side panels 636. The outer dimensions of the lower box member 630 are sized to be received within the interior dimensions of the upper box member 530.

A region 670 of increased flexibility extends transversely with respect to an axis of the lower box member 630, and includes transversely extending score lines 672 on the main panel 632. The flexible region 670 also includes openings 676 in the side walls 636, which are preferably elongate slits having enlarged openings 680 at each end. The flexible regions 570 and 670 are aligned when the lower box member 630 is received within the upper box member 530. The upper member 530 and the lower member 630 of the box 430 may be secured together for shipping via a number of methods, including an adhesive or adhesive tape, shrink wrap, or other fastener type.

FIG. 9 discloses a further embodiment mailer 730 comprising a single outer sleeve. FIG. 10 discloses a further embodiment mailer 830 comprising an outer sleeve 730 and an inner sleeve 330. The embodiments of FIGS. 9 and 10 omit end closure flaps and should include a separately applied means for retention of the mailer contents. Preferably, an outer shrink wrap layer is provided therefore.

Referring to FIG. 9, the mailer 730 may be substantially as described above with respect to FIG. 1, but wherein the end closure flaps are omitted. The outer sleeve 730 includes an upper main panel 732 and an opposing lower main panel 734. Opposing first and second upstanding side walls 736 and 738, respectively, extend between the upper panel 732 and the lower panel 734.

A region 770 of increased flexibility extends transversely with respect to an axis of the mailer 730, and includes transversely extending score lines 772 on the upper panel 732 and corresponding score lines (not shown) on the lower panel 734. The flexible region 770 also includes openings 776 in the side wall 736 and corresponding openings (not shown) in the side wall 738. The openings 776 and 778 are preferably elongate slits having enlarged openings 780 at each end. An exemplary address region 782 is shown in the illustrated embodiment, e.g., for printing or affixing an address, or which may be an opening or window to allow visualization of a preprinted address therethrough.

Referring now to FIG. 10, there appears a further embodiment mailer system including an outer box 730, which may be as described above by way of reference to FIG. 9, and which further includes an inner sleeve 330, which may be as described above by way of reference to the inner sleeve 330 shown in FIG. 7. The inner sleeve 330 has an outer dimension that is sized to be received within the interior of the outer sleeve 730.

When the inner sleeve member 330 is received within the outer sleeve member 730, the flexible region 370 is in axial alignment with the flexible region 770 of the outer sleeve member 730. The inner sleeve 370 may optionally be fixed to the outer sleeve 730 via fastener as described above. The sleeve 330 may include an address region 382 aligned with the region 782. In the case of an outer sleeve 730 having an opening or window 782, the region 382 may have an address or address label thereon to be viewed through the window 782. Alternatively, the region 382 may be an opening or window for viewing an address printed on the contents to be mailed. An outer shrink wrap layer or other separately applied end closure means may be applied for retention of the mailer contents.

Referring now to FIG. 11, the sleeve 730 may be formed from a flat blank 731, which may be formed as described above of a suitable foldable sheet material for folding to form a generally rigid sleeve. The blank 731 includes score lines 90 and 92 defining the opposite long edges of the upper panel 732.

The blank 731 further includes score lines 94 and 96 defining the opposite long edges of the lower panel 734. Score lines 772 transversely extend across the upper panel 732 between the fold lines 90 and 92. Score lines 774 transversely extend across the lower panel 734 between the score lines 94 and 96. The slits 776 in the assembled mailer 730 may be preformed in the blank 731 and extend transversely between the fold lines 92 and 94 to define panels 777 therebetween. The slits 778 a and 778 b in the sidewall panels 738 a and 738 b, respectively, overlap in the assembled mailer 730 to form slits 776 in the sidewall 738 of the assembled mailer. The enlarged openings 80 in the assembled mailer are formed by the openings 80 and the cutout regions 80 a and 80 b which may likewise be precut on the blank 731. If openings are to be provided in the regions 782 and/or 783, such openings may be die cut or otherwise preformed in the blank 731.

In constructing the mailer 730 from the blank 731, the blank is folded at right angles along the lines 90, 92, 94, and 96 and the flaps 738 a and 738 b are secured together in overlapping fashion to form the side wall 738. The flaps 738 a and 738 b may be secured together with an adhesive, mechanical fastener, or other fastening technique as described above.

A shrink wrap layer or other end closure means may be provided to retain the contents within the assembled mailer. The inner sleeve member 330 (see FIGS. 7, 10) may be formed in the same fashion and is dimensioned to be telescopically received within the outer sleeve or box. Although the embodiments of FIGS. 9-11 include a single, centrally located region of increased flexibility it will be recognized that a plurality of such flexible regions may be provided as detailed above.

FIG. 12 discloses a further embodiment mailer 800 comprising a single outer sleeve 830. FIG. 13 discloses a further embodiment mailer 900 with an inner packaging tray 930. Yet a further embodiment mailer 960 with an inner packaging component 962 is disclosed in FIG. 14. The embodiments of FIGS. 12, 13, and 14, as depicted in the illustrated embodiments, omit end closure flaps and may include a separately applied means for retention of the mailer contents. For example, an outer shrink wrap layer or an adhesive closure may be provided therefore. In alternative embodiments, not shown, the mailers 800, 900, and 960 may be modified to include end closure flaps on the outer shell component 830.

Referring now to FIG. 12, the mailer 800 may be substantially as described above with respect to FIG. 9, but wherein a flexible region 870 includes one generally rectangular opening 876 in a first upstanding side wall 836 and a like, axially-aligned opening 878 in a second upstanding side wall 838. The outer sleeve 830 includes an upper main panel 832 and an opposing lower main panel 834. The opposing first and second upstanding side walls 836 and 838, respectively, extend between the upper panel 832 and the lower panel 834.

The region 870 of increased flexibility extends transversely with respect to an axis of the mailer 800, and includes a transversely extending score line 872 on the upper panel 832 and corresponding transversely extending score line 874 on the lower panel 834. The opening 876 formed in the side wall 836 and the corresponding aligned opening 878 formed in the side wall 838 cooperate with the preferential fold lines 872 and 874 to define the flexible region 870.

A single region 870 of preferential folding is depicted in the exemplary embodiment of FIG. 12. It will be recognized, however, that other numbers of flexible regions may be provided. In the depicted embodiment, each of the upper and base panels 832 and 834 have a single score line, 872 and 874, respectively, and each of the sidewalls 836 and 838 have a single opening, 876 and 878, respectively. However, it will be recognized that other numbers of score lines and/or side panel openings per flexible region are also contemplated. The openings 876 and 878 are preferably rectangular openings although other opening configurations are contemplated.

An optional, exemplary address region 882 is shown in the illustrated embodiment, e.g., for printing or affixing an address. Alternatively, the region 882 may be an opening or window, e.g., which allows visualization of a preprinted address or package contents therethrough.

Referring now to FIG. 13, there appears a further embodiment mailer system 900 including an outer sleeve 830, which may be as described above by way of reference to FIG. 12, and which further includes an inner sleeve or tray 930. The inner sleeve or tray 930 has an outer dimension that is sized to be received within the interior of the outer sleeve 830. The inner sleeve 930 includes a main panel 932 and one or more lower base panels 944. The main panel 932 is aligned with the corresponding panel 832 and the base panels 944 are aligned with the corresponding panel 834 of the outer sleeve 830. Opposing first and second upstanding side walls 936 and 938, respectively, extend generally vertically down from the panel 932. Opposing third and forth upstanding side walls 946 and 948, respectively, extend between the main panel 932 and the lower base panels 944. Alternatively, the base panels 944 may be replaced with a peripheral flange circumscribing the tray 930.

A region 970 of increased flexibility extends transversely with respect to an axis of the inner sleeve member 930, and includes one or more transversely extending areas of preferential folding 950 on the upper panel 932. The preferential fold area 950 may also be formed in the side walls 938 and 940 to further define the flexible region 970. The inner sleeve or tray 930 may include one or more compartments 952, e.g., molded compartments, to contain items during shipping. The molded compartment 952 may be placed anywhere on the main panel 932 except in the flexible region 970. The molded compartment 952 should not pass through or be located in the flexible region 932 since bending or flexing could cause damage to the item(s) being shipped as the mail piece passes through postal handling or processing equipment.

The inner sleeve or tray 930 may be formed of a molded plastic material and the areas of preferential folding 950 could be a molded feature, such as a molded channel or groove. Alternatively, the inner sleeve or tray could be formed of paperboard or other sheet material and the region of preferential folding could be formed by providing one or more score lines on the upper panel and one or more openings in the side walls in accordance with this teaching.

When the inner sleeve member 930 is received within the outer sleeve member 830, the flexible region 970 is in axial alignment with the flexible region 870 of the outer sleeve member 830. The inner sleeve 930 may optionally be fixed to the outer sleeve 830 via fastener as described above. The sleeve 930 may also include an address region aligned with the region 882. In the case of an outer sleeve 830 having an opening or widow in the region 882, the address region may have an address label thereon to be viewed through the window 834. Additional openings may be provided on the outer sleeve 830, e.g., to allow visualization of the package contents therethrough. Where one or more openings are provided, such openings could be covered with a transparent film applied to the inner sleeve 930 or to the outer sleeve 830. In the alternative, the openings could be uncovered and an outer shrink wrap layer may be provided for retention of the mailer contents.

Referring now to FIG. 14, there appears a further embodiment mailer system 960 including an outer sleeve 830, which may be as described above by way of reference to FIGS. 12 and 13, and which further includes an inner mailing substrate 962, wherein the entire inner substrate 962 is flexible. The inner substrate 962 has an outer dimension that is sized to be received within the interior of the outer sleeve 830. In the depicted embodiment, the inner substrate 962 includes an upper layer 964 and a lower layer 966. The top of the upper layer 964 is aligned with the corresponding panel 832 and the bottom of lower layer 964 is aligned with the corresponding panel 834 of the outer sleeve 830.

In the depicted embodiment, the panels 964 and 966 are formed from a sheet of flexible material adapted to be folded in half. Alternatively, the panels 964 and 966 may be separate sheets. In the depicted embodiment, a slit 968 is formed along the midpoint of the substrate 962 and one or more points of attachment 969 remain to enable the two flexible layers 964 and 966 to be hingedly connected and to lay flat against each other, thereby preventing extra bulk from being created in the inner substrate 962. The main panel 964 may contain one or more compartments or cutout regions 971, 973 to hold items during shipping, including objects, documents containing a mailing address, etc. For example, the cutout 970 provides a slot for receiving items to be mailed and the cutout 972 provides a slot to insert documents and enable the mailing address printed on those documents to be seen through an aligned address window 882.

The depicted embodiment is exemplary only, and other configurations are contemplated. For example, if multiple items are to be shipped, additional cutouts 971, 973 could be formed in the inner substrate 962. The cutouts 971, 973 may be shaped to conform to the shape of the objects being mailed and may be placed anywhere on main panels 964, 966 except in portion aligned with the flexible region 870 of the outer sleeve 830. The cutouts 971, 973 should not pass through or lie in the areas corresponding to flexible region 870 if the item(s) could be damaged if bent or flexed because mailer system 960 will bend or flex along the flexible region 870 as it passes through the postal handling or processing system.

Additional openings such as the exemplary address region 882 appearing in the illustrated exemplary embodiment may be added to the outer sleeve 830. The region 882 may be an opening or window to allow visualization of the packages contents therethrough. Such opening could be covered with a transparent film to enable viewing of the packages contents without the risk of the contents being removed or lost during shipping. The transparent film could be applied to the inner sleeve 962 or to the interior or exterior of the outer sleeve 830. In the alternative, the entire package could be shrink wrapped to ensure the package contents are retained during shipping.

In an alternative embodiment, the flexible substrate 962 may be comprised of one or more separate layers of flexible material stacked together. In other embodiments, the substrate 962 may be comprised of one or more layers of flexible material hingedly connected and folded multiple times. It will be recognized that the flexible substrate depicted herein is exemplary and illustrative only and any other known alternative flexible layer may be employed, including variations in the number of connected or independent flexible layers, or the like. The flexible insert may be formed of a flexible polymeric foam material, such as polyurethane, polystyrene, or other open or closed cell foam material, to allow flexing of the mail piece as well as provide protection to the contents during handling.

Referring now to FIG. 15, the sleeve 830 appearing in FIGS. 12-14 may be formed from a flat blank 831, which may be formed as described above of a suitable foldable sheet material for folding to form a generally rigid sleeve. The blank 831 includes score lines 90 and 92 defining the opposite long edges of the upper panel 832. The blank 831 further includes score lines 94 and 96 defining the opposite long edges of the lower panel 834.

One or more score lines 872 extend transversely across the upper panel 832 between the fold lines 90 and 92. One or more score lines 874 extend across the lower panel 834 between the score lines 94 and 96. Score lines 92 and 94 define the opposite long edges of the first upstanding side wall 836. The rectangular opening 874 in the assembled mailer 830 may be preformed in the blank 831 and extend transversely between the fold lines 92 and 94. The cutouts 878 a and 878 b in the sidewall panels 838 a and 838 b, respectively, overlap in the assembled mailer 830 to form the opening 878 in the sidewall 838 of the assembled mailer. If openings are to be provided in the panels 832, 834, such as the regions 882 and/or 883, such openings may be die cut or otherwise preformed in the blank 831.

In constructing the mailer 830 from the blank 831, the blank is folded at right angles along the lines 90, 92, 94, and 96 and the flaps 838 a and 838 b are secured together in overlapping fashion to form the side wall 838. The flaps 838 a and 838 b may be secured together with an adhesive, mechanical fastener, or other fastening technique as described above.

A shrink wrap layer or other end closure means may be provided to retain the contents within the assembled mailer. The inner sleeve member 930 is dimensioned to be telescopically or slidably received within the outer sleeve or box 830. Although the embodiments of FIGS. 12-15 include a single, centrally located region of increased flexibility it will be recognized that a plurality of such flexible regions may be provided as detailed above. Also, end closure flaps are omitted in the blank 831. In alternative embodiments, the blank 831 could be modified to include end closure flaps as described above if desired.

Referring now to FIGS. 16 and 17, there is illustrated an exemplary embodiment mailer 430 having an upper main panel 432 and an opposing lower main panel 434, the upper and lower panels 432 and 434 being generally planar and generally rectangular and of substantially the same dimension. Opposing first and second upstanding side walls 436 and 438, respectively, extend between the upper panel 432 and the lower panel 434. An opening 442 is defined at a first end, shown generally as 440, of the mailer 430, with the opposite end of the mailer 430 being shown generally as 460.

One or more closure flaps may be provided to close the opening 442. In the depicted embodiment, a pair of lateral closure flaps 436 and 438 is attached to the side walls 436 and 438, respectively. An end closure flap 450 is attached to the upper panel 432 and includes a distal portion 452 to be received through the opening 442. The end closure flap 450 also includes a proximal portion 454, which extends vertically between the upper and lower panels 432 and 434. The proximal portion 454 further defines an end panel for covering the opening 442 when the end closure flap 450 is in the closed position.

A region 470 of increased flexibility extends transversely with respect to an axis of the mailer 430, preferably the long axis of the mailer 430, and includes one or more score lines 472 (shown in broken lines) extending transversely across the upper panel 432. A corresponding one or more score lines 474 extend transversely across the lower panel 434. Openings 476 and 478 are formed in each of the side walls 436 and 438, respectively. The openings 466 and 478 are preferably generally rectangular openings although other configurations are contemplated.

As depicted, each of the openings 476 and 478 extends between one of the upper panel score lines 472 and an axially aligned one of the lower panel score lines 474. The flexible region 470 thus contains an opening 476 and 478 in each of the side walls 436 and 438 and may contain one or more score lines 472, 474 on the upper and lower panels 432, 434, respectively. The score lines 472 and 474 extend between the openings 476 and 478. In alternative embodiments, each of the score lines 432 and 434 may be replaced with a plurality of parallel scorelines extending transversely between the openings 476 and 478.

Referring now to FIG. 18, and with continued reference to FIGS. 16 and 17, the mailer 430 may be formed from a flat blank 431 as seen in FIG. 18. As discussed above, a blank, such as blank 431, may be formed of any suitable material for folding to form a generally rigid box, such as paperboard, cardboard, card stock, plastic, plastic-coated paper, or other foldable sheet material. The blank 431 may be cut to the desired size and preferred shape, and the openings, score lines, etc., as described herein may be formed thereon via conventional methods, such as die cutting from one or more sheets of stock material.

The blank 431 includes score lines 90 and 92 defining the opposite long edges of the upper panel 432. The blank 431 further includes score lines 94 and 96 defining the opposite long edges of the lower panel 434. Score lines 108 provide preferential fold lines for the lateral flaps 448. Score lines 100 are provided on each of the flaps 450 to provide a preferential fold line on each flap 450 between the proximal and distal portions 454 and 452, respectively.

A score line 472 extends transversely across the upper panel 432 between the fold lines 90 and 92. A score line 474 extends transversely across the lower panel 434 between the score lines 94 and 96. The opening 476 in the assembled mailer 430 may be preformed in the blank 431 and extend transversely between the fold lines 92 and 94. The cutouts 478 a and 478 b in the sidewall panels 438 a and 438 b, respectively, overlap in the assembled mailer 430 to form the opening 478 in the assembled mailer. If openings are to be provided in the exemplary regions 482 and/or 483, such openings may be die cut or otherwise preformed in the blank 431.

In constructing the mailer 430 from the blank 431, the blank is folded at right angles along the lines 90, 92, 94, and 96 and the flaps 438 a and 438 b are secured together in an overlapping fashion to form the side wall 438. The flaps 438 a and 438 b may be secured together with an adhesive, mechanical fastener, or other fastening technique, as described above.

To close one or both of the ends 440 and 460 of mailer 430, the end flaps 450 are each folded along the fold lines 98 and 100. The distal portions 452 are inserted within the respective openings 442 such that the proximal portions 454 each form a peripheral end wall extending between the upper panel 432 and the lower panel 434. A shrink wrap layer or other end closure means such as tape or other adhesive closure member may be provided to ensure flaps 450 do not open and spill the contents of the assembled mailer. The embodiment 430 shown in FIGS. 16 and 17 may be employed with any of the inner sleeves, trays, or substrates as shown and described herein.

The postal mailers herein may be dimensioned as a flat-size mail pieces, including automation rate flat-size mail pieces. In certain embodiments, the postal mailers may be generally rectangular wherein the main panels each have a pair of opposing edges having a length in the range of about 4 inches to about 12 inches, a second pair of opposing edges having a length in the range of about 4 to about 15.75 inches, and a thickness in the range of about 0.009 to about 1.25 inches. In certain other embodiments, the postal mailers may be generally rectangular wherein the main panels each have a pair of opposing edges having a length in the range of about 5 inches to about 12 inches, a second pair of opposing edges having a length in the range of about 6 to about 15 inches, and a thickness in the range of about 0.009 to about 0.75 inches.

The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 

1. A postal mailer, comprising: a first main panel and a second main panel opposite said first main panel; opposed first and second peripheral side panels extending between said first main panel and said second main panel; one or more score lines extending across each of said first and second main panels; and a single opening formed in each of said first and second peripheral side panels and extending between said first and second main panels.
 2. The postal mailer of claim 1, wherein said opening comprises a generally rectangular opening.
 3. The postal mailer of claim 1, wherein said first and second main panels and said first and second peripheral side panels define a sleeve having an opening at each end.
 4. The postal mailer of claim 1, further comprising: opposed first and second end panels extending between said first main panel and said second main panel.
 5. The postal mailer of claim 4, wherein said first and second end panels include end closure flaps.
 6. The postal mailer of claim 1, further comprising: said one or more score lines extending across each of said first and second main panels and said opening formed in each of said first and second peripheral side panels and extending between said first and second main panels cooperating to provide a region of preferential bending when said postal mailer is processed by postal processing equipment.
 7. The postal mailer of claim 1, wherein each of said one or more score lines extending across said first main panel and each of said one or more score lines extending across said second main panel extend in a direction perpendicular to an axis of the postal mailer.
 8. The postal mailer of claim 1, wherein said postal mailer is elongate and wherein each of said one or more score lines extending across said first main panel and each of said one or more score lines extending across said second main panel extend in a direction perpendicular to a longitudinal axis of the postal mailer.
 9. The postal mailer of claim 1, wherein each of said one or more score lines extending across said first main panel is parallel to and axially aligned with a corresponding one of said one or more score lines extending across said second main panel.
 10. The postal mailer of claim 9, wherein said opening comprises a generally rectangular opening extending in axial alignment with said one or more score lines extending across said first main panel and said one or more score lines extending across said second main panel.
 11. The postal mailer of claim 1, wherein said one or more score lines extending across each of said first and second main panels and said opening in each of said first and second peripheral side panels cooperate to define at least one region of increased flexibility which extends transversely with respect to an axis of said postal mailer.
 12. The postal mailer of claim 11, wherein said postal mailer is elongate and said axis is a longitudinal axis.
 13. The postal mailer of claim 11, wherein said at least one region of increased flexibility includes a region of increased flexibility which is generally centrally positioned along said axis.
 14. The postal mailer of claim 1, further comprising: a shrink wrap layer covering the postal mailer.
 15. The postal mailer of claim 1, wherein said postal mailer is formed of a foldable sheet material selected from the group consisting of paperboard, cardboard, card stock, plastic, and plastic-coated paper.
 16. The postal mailer of claim 1, wherein said first main panel, said second main panel, and said first and second peripheral side panels are dimensioned as a flat-size mail piece.
 17. The postal mailer of claim 1, further comprising an inner mail piece dimensioned to be slidably received within said postal mailer, said inner mail piece selected from the group consisting of: an inner sleeve having at least one region of increased flexibility which is substantially aligned with said one or more score lines extending across each of said first and second main panels and said opening formed in each of said first and second peripheral side panels and extending between said first and second main panels; an inner substrate formed of a flexible polymeric foam material; and an inner tray.
 18. The postal mailer of claim 17, wherein the inner tray is a molded plastic tray having one or more compartments for receiving an item to be mailed.
 19. The postal mailer of claim 1, further comprising: said first and second main panels being generally rectangular and of substantially the same dimension; each of said first and second main panels having a first pair of opposing edges having a length in the range of about 4 to about 12 inches and a second pair of opposing edges having a length in the range of about 4 to about 15.75 inches; and each of said opposing sidewalls having a thickness in the range of about 0.009 inches to about 1.25 inches.
 20. A postal mailer blank, comprising: a plurality of wall panels hingedly connected together for forming a first main panel, a second main panel opposing said first main panel, and first and second opposing side walls; one or more score lines extending across said first main panel and one or more score lines extending across said second main panel; and a first opening for forming a first opening in said first opposing side wall; a second opening for forming a second opening in said second opposing side wall; said first and second openings aligned with each other and with said one or more score lines extending across said first main panel and said one or more score lines extending across said second main panel. 